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Strata EZITIG 180 Operating Instructions Manual

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EZITIG 18 0
OPERATING INSTRUCTIONS
MULTI-PROCESS TIG WELDER
CONSTANT
CURRENT
www.strata.co.nz
2www.strata.co.nz
EZITIG 180
Congratulations on your new Strata product!
The Strata range from Euroquip uses latest technology design and engineering to produce
welding products that combine market leading value and features with durability. Designed
for discerning operators who seek professional results and product quality without the price
tag of a full professional setup. Design emphasis is placed on simple, functional design
and operation. Strata product is subject to stringent quality control and designed and
manufactured to NZ & Australian standards.
Common use of Strata products include:
• LightEngineering
• Automotive
• Home/HobbyEngineering
• Farming
• IndustrialMaintenance&Repairs
Forindustrialweldingsolutions,checkouttheStratarangefromEuroquip:
www.strata.co.nz
Euroquip is a market leading provider of innovative power equipment solutions to a wide
range of industries across New Zealand and Australia. Key product categories are; welding
equipment, air compressors, power generators and cleaning equipment.
Euroquip’s slogan is ‘empowering industries’, find out more about the advantage Euroquip
brings at www.euroquip.co.nz.
Providing exceptional product support is a key component of Euroquip’s market leading
customer advantage focus. As part of this program, it is required for all products to be
registered with Euroquip to qualify for product support. Products not registered with Euroquip
are supported by a base 12 month warranty only. Spare parts and technical support will not
beavailableforanunregisteredproductoutsideofthisbasewarrantyperiod.IfaEuroquip
dealer has not already registered your product, please register it online at www.euroquip.
co.nz. To request a physical registration form, please download one at www.euroquip.co.nz
under the ‘Contact Us’ tab.
3
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EZITIG 180
Contents
KnowYourMachine............................................................5
Quick Start Guide................................................................6
Available Parts & Accessories..............................................7
3PinRemotePlugConnection...........................................8
Wiring Diagram...................................................................9
Care&Maintenance..........................................................10
Electrodes.........................................................................10
EffectsofMMAWeldingVariousMetals...........................11
BasicMMAWeldingGuide..............................................12
MMAWeldingTechniques.................................................13
OtherKnowledge&Resources.........................................16
MMATroubleshooting......................................................17
TIGWeldingGuide............................................................18
TIGTroubleshooting.........................................................20
Safety..............................................................................21
Warranty.........................................................................27
4www.strata.co.nz
EZITIG 180
• EZITIG 180 •
MULTI-PROCESS TIG WELDER
The EZITIG 180 is a powerful, extremely portable and easy to use TIG & MMA (Stick) unit. Extreme
stress tested to 440V from the factory with IP23 moisture and salt spray protection, the EZITIG
180 has protection against the most harshest environments. Featuring the HF Start and 180A DC
current, it is ideal for mild and stainless steel work such as wine vats, maintenance roll cages
and industrial TIG work.
• IGBTInvertertechnologyforsmooth&stable 
welding output and increased reliability
• Microprocessorcontrolsystemforsuperior& 
dynamic arc characteristics
• Lightweight&compactdesign,idealforportable
applications
• Extremestresstestedinproductionupto440Vfor
rugged reliability
• Strongenvironmentalprotectionforprotection
againt moisture, salt spray and corrosion
• Automaticarcforce,hotstart&antistickcontrolfor
 greatercontrolandeaseofusewhenMMAwelding
• HFTIGarcignitionsystemforcontaminationfree
and easy arc starting
• 2T/4ttriggercontrol
• Digitaldisplaymeterforaccuratesetting&
feedback of welding output
• Highquality&overspecifiedelectroniccomponents
for durability & reliability
• Quickconnectinletgasfittingforeaseofuseand
changing bottles between machines.
DIMENSIONS: WEIGHT: INPUT POWER MAX. INPUT GENERATOR CURRENT MMA O/C DUTY CYCLE: STANDARDS: MAX WELD
SUPPLY: CURRENT: CAPACITY: OUTPUT: VOLTAGE: THICKNESS:
410x146x278mm 5.5kg 230VAC15A 40A 9.8KVA 10-180A 74V 60%@125A EN60974-1:2012 8mm
50Hz    
CONSTANT
CURRENT
5
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EZITIG 180
*Denotes more detailed explanation of function to follow.
1. Digital current display meter
2. Welding output mode switch. Sets power
 sourceinTIG2T,TIG4TorMMAmode*
3. TIGpostgasflowcontrolknob*
4. Down slope control knob*
5. Positive (+) welding power output connection socket
6. TIGtorchgasconnector
7. Negative(-)weldingpoweroutputconnection socket
8. TIGtorchremoteconnectionsocket
9. Welding current control knob
10. PowerIndicator.Lightswheninputpower
connected and machine switched on
11. Error/OverloadIndicator*
Further Controls Explained
Overload/ Error Indicator
Lightswhenovervoltage,overcurrentorelectrical
overheating (due to exceeding duty cycle) is detected
and protection is activated. When protection is acti-
vated, welding output will be disabled until the safety
system senses the overload has reduced sufficiently
andindicatorlampgoesout.Mayalsotriggerifma-
chine experiences an internal power circuit failure.
TIG 2T/4T
In2Tmodethetriggerispulledandheldontoacti-
vate the welding circuit, when the trigger is released,
the welding circuit stops. 4T is known as ’latching’
mode. The trigger is pulled once and released to ac-
tivate the welding circuit, pulled and released again
to stops the welding circuit. This function is useful to
longer welds as the trigger is not required to be held
on continuously.
Post Flow
Controls the period of time the shielding gas contin-
ues to flow for after the arc is stopped. This protects
the weld area and torch tungsten from contamination
while it is still hot enough to react with atmospheric
gases, after the weld is finished.
Down Slope
When the trigger is released, the welding current will
reducegraduallyoverthetimeselecteddownto0.
This allows the operator to complete the weld without
leaving a ‘crater’ at the end of the weld pool.
Tips & Tricks
Duty Cycle Rating
Welding duty cycle is the percentage of actual weld-
ing time that can occur in a ten minute cycle. E.g.
20%at160amps-thismeanstheweldercanweldat
160ampsfor2minutesandthentheunitwillneedto
berestedfor8minutes.
All duty cycle ratings are based on an ambient air
temperatureof40°Cwith50%humidity,whichisthe
internationalstandardforsucharating.Inanenvi-
ronmentwithtemperaturesexceeding40°C,theduty
cyclewillbelessthanstated.Inambienttemperature
lessthan40°C,dutycycleperformancewillbehigher.
Know Your Machine 1
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2
4
5
6
7
8
9
10
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6www.strata.co.nz
EZITIG 180
Electrical Connection
TheEZITIG180isdesignedtooperateona15A230V
ACpowersupply.Ifanextensioncordmustbeused,
it should be a heavy duty version with a minimum
cablecoresizeof2.5mm2.Itisrecommendedtouse
theEuroquipindustrialduty15Aextensionlead,part
number;16895.
Operating Environment
Adequate ventilation is required to provide proper
coolingfortheEZITIG180.Ensurethatthemachine
is placed on a stable level surface where clean cool
aircaneasilyflowthroughtheunit.TheEZITIG180
has electrical components and control circuit boards
which may be damaged by excessive dust and dirt, so
a clean operating environment is important for reli-
able product life.
Basic Operation
1. ARC/ MMA Welding Operation
1.1 Connect the earth cable quick connector to the
negative welding power output socket (7) Con-
nect the earth clamp to the work piece. Contact
with the work piece must be firm contact with
clean, bare metal, with no corrosion, paint or
scale at the contact point.
1.2 Insertanelectrodeintotheelectrodeholderand
connect the electrode holder and work lead to
thepositiveweldingpoweroutputsocket(5).
Note: This polarity connection configuration is valid for most
GP(GeneralPurpose) MMAelectrodes.There are variancesto
this.Ifindoubt,checktheelectrodespecificationsorconsultthe
electrode manufacturer.
1.3 Connect the machine to suitable mains power
using the mains input power lead. Switch the
mains power switch to ‘on’ to power up the
machine. Set the welding mode switch (2) to
‘MMA’.
1.4 Select the required output current using the
current control knob (9). You are now ready to
weld!
Quick Start Guide - Welder Installation
2. TIG Operation
Note:TIGoperationrequiresanargongassupply.
2.1 Connect the earth cable quick connector to the
positiveweldingpoweroutputsocket(5).Con-
nect the earth clamp to the work piece. Contact
with the work piece must be firm contact with
clean, bare metal, with no corrosion, paint or
scale at the contact point.
2.2 InsertTIGtorchpowerconnectionintothenega-
tive welding power output socket (7). Connect
TIGtorchremoteplugtoremotesocket(8)and
torchgasconnectiontotheTIGgasoutlet(6).
2.3 Connect the machine to suitable mains power
using the mains input power lead. Switch the
mains power switch to ‘on’ to power up the ma-
chine. Select ‘2T’ or ‘4T mode using the mode
selector switch (2).
2.4 Assemble the female gas quick connector to
the gas line and to the regulator outlet fitting.
Connect the gas regulator to a gas cylinder (not
included with machine) and connect the female
quick connector to the male gas inlet on the rear
of the machine. Ensure all connections are tight.
Open gas cylinder valve and adjust regulator,
flowshould bebetween 5-10l/min depending
onapplication.Re-checkregulatorflowpressure
with the torch triggered as static gas flow setting
may drop once gas is flowing.
2.5 Settheweldingcurrent(9),downslope(4)and
gas post flow (3) as required. You are now ready
to weld!
Pleasenote,theEZITIG180isaDC(DirectCurrent)outputwelder
only.ThismeansthatitisunabletoTIGweldreactivemetalssuch
asAluminiumalloysandBrass(whichrequireACoutput).DCTIG
output is suitable for steel, stainless steel and copper.
TheADVANCETIGAC/DCseriesarethemodelsdesignedforTIG
welding Aluminium and its alloys.
7
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EZITIG 180
Available Parts & Accessories
EZITIG 180:
7370 Pro-Grip26TorchX12.5Ft,TgcEnd
 (LargeDinse)M12And3PinHizonePlug
AAL3550 ArcLead16mm2Cable,35-70mmPlug,4m
AEL3550 EarthLead16mm2Cable,35-70mmPlug,3m
ALS3550 MMALeadSet300A3mEarth+4mArc,
 1/2”DinseConnectors
S400EH 400AScrewTypeElect.Holder
S500EC Strata500aEarthClamp
CP3550 CablePlug-35-50mm³-Male
DW3000 AutoDarkeningHelmet,Shade9-13
DW4000 AutoDarkeningHelmet,Shade9-13
 withGrindingVisor
GR101AR ArgonTwinGaugeRegulator
GR101ARFL ArgonGasRegulatorc/wFlowMeter
GR101AR-2FL ArgonRegulatorc/wTwinFlowMeter
16895 15mH/D15AExtensionLead(3x2.5mm2wiring)
TBC57Y02 LongBlackCap
TC10N23 Collet1/16(1.6mm)(2pk)
TC10N24 Collet3/32(2.4mm)(2pk)
TC10N25 Collet1/83.2mm(Pkt2)
TCB10N31 ColletBody1/16(1.6mm)(2pk)
TCB10N32 ColletBody3/32(2.4mm)(2pk)
TCB10N28 ColletBody1/8(3.2mm)(2pk)
TCC10N48 Std.CeramicCup3/8bore#6(2pk)
TCC10N47 Std.CeramicCup7/16bore#7(2pk)
TCC10N46 Std.CeramicCup1/2bore#8(2pk)
TCC10N45 Std.CeramicCup5/8bore#10(2pk)
TheseaccessorieslistedareavailablefromyourStrataSupplier.RefertotheStrataCatalogue,yourStrataSupplier
or look online at www.strata.co.nz for other accessories and consumables available.
TT16-150 ThoriatedTungstenElectrode1.6mm(3pk)
TT24-150 ThoriatedTungstenElectrode2.4mm(3pk)
TT32-150 ThoriatedTungstenElectrode3.2mm(3pk)
DCKIT DCTigComponentsStarterKit-WP17,WP18,
WP26 Suits:XTP200PRO,XMP5000
 SuitsanyTIGKitsoldwithMIGorARCwelder
TR16MS-70S-6 MildSteelTIGRod1.6mm/1kg
TR24MS-70S-6 MildSteelTIGRod2.4mm/1kg
TR32MS-70S-6 MildSteelTIGRod3.2mm/1kg
TR16SS-316 StainlessSteelTIGRod1.6mm
TR24SS-316 StainlessSteelTIGRod2.4mm
TR32SS-316 StainlessSteelTigRod3.2mm
ETCPH4825 OvercordR922.5mmElectrodes(350mm)
ETCPH4832 OvercordR923.2mmElectrodes(350mm)
ETCPH4840 OvercordR924.0mmElectrodes(350mm)
ETCPH6825 Overcord2.5mmElectrodes(350mm)
ETCPH6832 Overcord3.2mmElectrodes(350mm)
ETCPH6840 Overcord4.0mmElectrodes(350mm)
ETCPH7725 Supercito2.5mmElectrodes(350mm)
ETCPH7732 Supercito3.2mmElectrodes(450mm)
ETCPH7740 Supercito4.0mmElectrodes(450mm)
ETCPH56S25 Tenax56S2.5mmElectrodes(350mm)
ETCPH56S32 Tenax56S3.2mmElectrodes(350mm)
ETCPH56S40 Tenax56S4.0mmElectrodes(450mm)
PDL15 Plug,3Pin15A250VStraight
17844 GasInletQC
17845 3PinStrataEziTig180RemotePlug
8www.strata.co.nz
EZITIG 180
3. TCB57Y02 BackCapLong
4. TCB57Y04 BackCapShort
5. TER1MS MomentaryKit
6. UERSWL8 TriggerLead25ft
8. TERH200 LargeErgoTigHandle
9. UERKJ200 LargeKnuckleJoint
11. UERJK200 JointingRepairKit
13. UERCO200-40 Sheathx12.5ftIncLeatherCover
 UERCO200-80 Sheathx25ftIncLeatherCover
15. 46V28 PowerCablex12.5ftRubber
 46V30 PowerCablex25ftRubber
Suregrip™ Series WP26 Torch Parts
AllproductsconformtoEN60974-7andareRoHS,REACHandWEEEcompliant
3 Pin Remote Plug Connection
12
33
2
1
Gun Switch
9
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EZITIG 180
Wiring Diagram
10 www.strata.co.nz
EZITIG 180
Care & Maintenance
Keep your Welding Machine
in Top Condition
TheEZITIG180doesnotrequireanyspecialmain-
tenance, however the user should take care of the
machine as follows:
• Regularlycleantheventilationslots.
• Keepthecasingclean.
• Checkallcablesbeforeuse.
• Checkelectrodeholders,worklead/clampsand
welding torches before use.
• Replacewornelectrodeholdersandearth
clamps, which do not provide a good
connection.
• Replacewornconsumablepartsinatimely
manner.
• Useasoftclothorbrushtocleanelectrical
components.
• Donotuseliquidcleaningproducts,wateror
especially solvents.
• Donotusecompressedairtocleanelectrical
components as this can force dirt and dust
further into components, causing electrical short
circuits.
• Checkfordamagedparts.Donotusethewelder
with damaged parts.
• Adamagedweldermustbecarefullycheckedby
a qualified person to determine that it will operate
properly. Check for breakage of parts, mountings
and other conditions that may affect its operation.
An authorised service centre should properly
repairadamagedpart.Haveyourwelderrepaired
by an expert.
This appliance is manufactured in accordance with
relevant safety standards. Only experts must carry
out repairing of electrical appliances, otherwise
considerable danger for the user may result. Use only
genuine replacement parts. Do not use modified or
non-genuineparts.
Storing the Welder
When not in use the welder should be stored in the
dryandfrost-freeenvironment.
WARNING! Before performingcleaning/main-
tenance,replacingcables/connections,make
sure the welding machine is switched off and
disconnected from the power supply.
Electrodes
Size of Electrodes
The electrode size is determined by the thickness of
metals being joined and can also be governed by the
type of welding machine available. Small welding ma-
chines will only provide current (amperage) to run
smaller sized electrodes.
Forthinsections,itisnecessarytousesmallerelec-
trodes otherwise the arc may burn holes through the
job. A little practice will soon establish the most suit-
able electrode for a given application.
Storage of Electrodes
Always store electrodes in a dry place and in their
original containers.
Electrode Polarity
Electrodes are generally connected to the electrode
holder with the electrode holder connected positive
polarity.
The work lead is connected to the negative polarity
andisconnectedtotheworkpiece.Ifindoubtconsult
the electrode data sheet.
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EZITIG 180
High Tensile and Alloy Steels
The two most prominent effects of welding these
steels are the formation of a hardened zone in the
weld area, and, if suitable precautions are not taken,
the occurrence in this zone of under-bead cracks.
Hardenedzoneandunderbeadcracksintheweldarea
may be reduced by using the correct electrodes, pre-
heating, using higher current settings, using larger
electrodes sizes, short runs for larger electrode de-
posits or tempering in a furnace.
Manganese Steels
The effect on manganese steel of slow cooling from
high temperatures causes embrittlement. For this
reason it is absolutely essential to keep manganese
steelcool during welding by quenching after each
weld or skip welding to distribute the heat.
Cast Iron
Mosttypesofcastiron,exceptwhiteiron,areweld-
able. White iron, because of its extreme brittleness,
generally cracks when attempts are made to weld it.
Trouble may also be experienced when welding
white-heartmalleable,duetotheporositycausedby
gas held in this type of iron.
Copper and Alloys
The most important factor is the high rate of heat
conductivityofcopper,makingpre-heatingofheavy
sections necessary to give proper fusion of weld and
base metal.
Types of Electrodes
ARCWeldingelectrodesareclassifiedintoanumber
of groups depending on their applications. There are
a great number of electrodes used for specialised in-
dustrial purposes which are not of particular interest
for everyday general work. These include some low
hydrogen types for high tensile steel, cellulose types
for welding large diameter pipes, etc. The range of
electrodes dealt with in this publication will cover the
vast majority of applications likely to be encountered;
are all easy to use.
MILD STEEL :
E6011-Thiselectrodeisusedforall-positionweldingor
forweldingonrusty,dirty,less-than-newmetal.Ithasa
deep, penetrating arc and is often the first choice for repair
or maintenance work.
E6013 -Thisall-positionelectrodeisusedforwelding
clean,newsheetmetal.Itssoftarchasminimalspatter,
moderatepenetrationandaneasy-to-cleanslag.
E7014 - All positional, ease to use electrode for use on
thickersteelthanE6013.Especiallysuitableforsheetmetal
lap joints, fillet welds and general purpose plate welding.
E7018-Alow-hydrogen,all-positionelectrodeusedwhen
qualityisanissueorforhard-to-weldmetals.Ithastheca-
pability of producing more uniform weld metal, which has
better impact properties at low temperatures.
CAST IRON:
ENI-CL -Suitableforjoiningallcastironsexceptwhite
cast iron.
STAINLESS STEEL:
E318L-16 -Highcorrosionresistances.Idealfordairy
work etc.
Electrodes for joining different metals
Effects of MMA Welding Various Materials
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EZITIG 180
Flat Position,
Down Hand Butt Weld
(Fig 1-11)
Flat Position,
Gravity Fillet Weld
(Fig 1-12)
Horizontal Position,
Butt Weld
(Fig 1-13)
Horizontal-Vertical
(HV) Position
(Fig 1-14)
Vertical Position,
Butt Weld
(Fig 1-15)
Vertical Position,
Fillet Weld
(Fig 1-16)
Overhead Position,
Butt Weld
(Fig 1-17)
Overhead Position,
Fillet Weld
(Fig 1-18)
Joint Preparations
Inmanycases,itwillbepossibletoweldsteelsec-
tions without any special preparation. For heavier
sections and for repair work on castings, etc., it will
be necessary to cut or grind an angle between the
pieces being joined to ensure proper penetration of
the weld metal and to produce sound joints.
In general, surfaces being welded should be clean
and free of rust, scale, dirt, grease, etc. Slag should
beremovedfromoxy-cutsurfaces.Typicaljointde-
signsareshowninFigure1-19.
Open Square Butt Joint (Fig
1-19a)
Gapvariesfrom1.6mm(1/16”)
to4.8mm(3/16”)dependingonplatethickness
Single Vee Butt Joint
(Fig 1-19b)
Notlessthan45°
Single Vee Butt Joint (Fig
1-19c)
Notlessthan70°
1.6mm(1/16”)max.
1.6mm(1/16”)
Double Vee Butt Joint (Fig
1-19d)
Notlessthan70° 1.6mm(1/16”)max.
1.6mm(1/16”)
Basic MMA Welding Guide
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EZITIG 180
Lap Joint (Fig 1-19e)
Fillet Joint (Fig 1-19f)
Corner Weld
(Fig 1-19g)
Tee Joints
(Fig 1-19h)
Edge Joint
(Fig 1-19i)
Plug Welds
(Fig 1-19j)
MMA Welding Techniques
A Word for Beginners
For those who have not yet done any welding, the
simplest way to commence is to run beads on a piece
ofscrapplate.Usemildsteelplateabout6.0mmthick
and a 3.2mm electrode.
Clean any paint, loose scale or grease off the plate
and set it firmly on the work bench so that welding
canbecarriedoutinthedownhandposition.Make
surethattheWorkLead/Clampismakinggoodelec-
trical contact with the work, either directly or through
theworktable.Forlightgaugematerial,alwaysclamp
the work lead directly to the job, otherwise a poor cir-
cuit will probably result.
The Welder
Place yourself in a comfortable position before begin-
ning to weld. Get a seat of suitable height and do as
much work as possible sitting down. Don’t hold your
body tense. A taut attitude of mind and a tensed body
willsoonmakeyoufeeltired.Relaxandyouwillfind
that the job becomes much easier. You can add much
to your peace of mind by wearing a leather apron and
gauntlets. You won’t be worrying then about being
burnt or sparks setting alight to your clothes.
Place the work so that the direction of welding is
across, rather than to or from, your body. The elec-
trode holder lead should be clear of any obstruction
so that you can move your arm freely along as the
electrodeburnsdown.Iftheleadisslungoveryour
shoulder, it allows greater freedom of movement and
takes a lot of weight off your hand. Be sure the insula-
tion on your cable and electrode holder is not faulty;
otherwise you are risking an electric shock.
Striking the Arc
Practice this on a piece of scrap plate before going on
to more exacting work. You may at first experience
difficultyduetothetipoftheelectrode“sticking”to
the work piece. This is caused by making too heavy
a contact with the work and failing to withdraw the
electrode quickly enough. A low amperage will accen-
tuateit.Thisfreezing-onofthetipmaybeovercome
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EZITIG 180
20o
1.6mm(1/16”)
Striking an Arc
(Fig 1-20)
Arc Length
The securing of an arc length necessary to produce a
neat weld soon becomes almost automatic. You will
find that a long arc produces more heat.
A very long arc produces a crackling or spluttering
noise and the weld metal comes across in large, ir-
regular blobs. The weld bead is flattened and spatter
increases. A short arc is essential if a high quality
weld is to be obtained although if it is too short there
is the danger of it being blanketed by slag and the
electrodetipbeingsolidifiedin.Ifthisshouldhappen,
give the electrode a quick twist back over the weld to
detachit.Contactor“touch-weld”electrodessuchas
E7014Stickelectrodesdonotstickinthisway,and
make welding much easier.
Rate of Travel
After the arc is struck, your next concern is to main-
tain it, and this requires moving the electrode tip to-
wards the molten pool at the same rate as it is melting
away. At the same time, the electrode has to move
along the plate to form a bead.
Making Welded Joints
Havingattainedsomeskillinthehandlingofanelec-
trode, you will be ready to go on to make up welded
joints.
A. Butt Welds
Set up two plates with their edges parallel, as shown
in Figure 1-21, allowing 1.6mm to 2.4mm gap be-
tween them and tack weld at both ends. This is to
prevent contraction stresses from the cooling weld
metal pulling the plates out of alignment.
Platesthickerthan6.0mmshouldhavetheirmating
edgesbevelledtoforma70ºto90ºincludedangle.
This allows full penetration of the weld metal to the
root. Using a 3.2mm E7014 Stick electrode at 100
amps, deposit a run of weld metal on the bottom of
the joint.
Do not weave the electrode, but maintain a steady
rate of travel along the joint sufficient to produce a
well-formedbead.Atfirstyoumaynoticeatendency
for undercut to form, but keeping the arc length short,
theangleoftheelectrodeatabout20ºfromvertical,
and the rate of travel not too fast, will help eliminate
this.
Tack Weld
Butt Weld
(Fig 1-21)
Electrode
20o-30o
Tack Weld
by scratching the electrode along the plate surface
in the same way as a match is struck. As soon as
the arc is established, maintain a 1.6mm to 3.2mm
gap between the burning electrode end and the par-
ent metal. Draw the electrode slowly along as it melts
down.
Another difficulty you may meet is the tendency, af-
ter the arc is struck, to withdraw the electrode so far
that the arc is broken again. A little practice will soon
remedy both of these faults.
Theelectrodeisdirectedattheweldpoolatabout20º
from the vertical. The rate of travel has to be adjusted
sothatawell-formedbeadisproduced.
Ifthetravelistoofast,thebeadwillbenarrowand
strung out and may even be broken up into individual
globules.Ifthetravelistooslow,theweldmetalpiles
up and the bead will be too large.
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EZITIG 180
Weld Build Up Sequence
(Fig 1-22)
Heavyplatewillrequireseveralrunstocompletethe
joint. After completing the first run, chip the slag out
andcleantheweldwithawirebrush.Itisimportant
to do this to prevent slag being trapped by the second
run. Subsequent runs are then deposited using either
a weave technique or single beads laid down
inthesequenceshowninFigure1-22.Thewidthof
weave should not be more than three times the core
wire diameter of the electrode.
When the joint is completely filled, the back is either
machined, ground or gouged out to remove slag
which may be trapped in the root, and to prepare a
suitablejointfordepositingthebackingrun.Ifaback-
ing bar is used, it is not usually necessary to remove
this, since it serves a similar purpose to the backing
run in securing proper fusion at the root of the weld.
B. Fillet Welds
These are welds of approximately triangular cross-
section made by depositing metal in the corner of two
facesmeetingatrightangles.RefertoFigure1-14,
1-23and1-24.
A piece of angle iron is a suitable specimen with which
to begin, or two lengths of strip steel may be tacked
togetheratrightangles.Usinga3.2mmE7014Stick
electrodeat100amps,positionangleironwithone
leg horizontal and the other vertical. This is known as
ahorizontal-vertical(HV)fillet.
Strike the arc and immediately bring the electrode to
a position perpendicular to the line of the fillet and
about45ºfromthevertical.Someelectrodesrequire
beingslopedabout20ºawayfromtheperpendicular
position to prevent slag from running ahead of the
weld.RefertoFigure1-23.
Do not attempt to build up much larger than 6.4mm
width with a 3.2mm electrode, otherwise the weld
metal tends to sag towards the base, and undercut
formsontheverticalleg.Multi-runscanbemadeas
showninFigure1-24.WeavinginHVfilletweldsis
undesirable.
Electrode Position for HV
Fillet Weld (Fig 1-23)
The electrode needs to be moved along fast enough
to prevent the slag pool from getting ahead of the arc.
To complete the joint in thin plate, turn the job over,
clean the slag out of the back and deposit a similar
weld.
C. Vertical Welds
1. Vertical Up
Tack weld a three feet length of angle iron to your
work bench in an upright position. Use a 3.2mm
E7014 Stick electrode and set the current at 100
amps.Makeyourselfcomfortableonaseatinfrontof
the job and strike the arc in the corner of the fillet. The
electrodeneedstobeabout10ºfromthehorizontalto
enableagoodbeadtobedeposited.ReferFig.1-25.
Multi-Runs in HV Fillet Weld
(Fig 1-24)
Single Run Vertical Fillet Weld
(Fig 1-25)
16 www.strata.co.nz
EZITIG 180
Weaving motion for
second and subsequent
runs
Pause at edge
of weave
Multi Run Vertical Fillet Weld (Fig
1-26)
Examples of Vertical Fillet Welds
(Fig 1-27)
Pause at edge of weave
allows weld metal to build
up and eliminates undercut
Note: Weld contour
when insufficient pause
at edge of weave
CORRECT INCORRECT
2. Vertical Down
TheE7014Stickelectrodemakesweldinginthisposi-
tionparticularlyeasy.Usea3.2mmelectrodeat100
amps. The tip of the electrode is held in light contact
with the work and the speed of downward travel is
regulated so that the tip of the electrode just keeps
ahead of the slag. The electrode should point up-
wardsatanangleofabout45º.
Theelectrodeisheldat45ºtothehorizontalandtilted
10ºinthelineoftravel(Figure1-28).Thetipofthe
electrode may be touched lightly on the metal, which
helps to give a steady run. A weave technique is not
advisable for overhead fillet welds.
Usea3.2mmE6013Stickelectrodeat100amps,and
deposit the first run by simply drawing the electrode
along at a steady rate. You will notice that the weld
deposit is rather convex, due to the effect of gravity
before the metal freezes.
Tilted10o in
line of travel
Overhead Fillet Weld
(Fig 1-28)
Angle tacked to pipe
45o to plate
Use a short arc, and do not attempt to weave on the
firstrun.Whenthefirstrunhasbeencompletedde-
slag the weld deposit and begin the second run at the
bottom. This time a slight weaving motion is neces-
sary to cover the first run and obtain good fusion at
the edges.
At the completion of each side motion, pause for a
moment to allow weld metal to build up at the edges,
otherwise undercut will form and too much metal
willaccumulateinthecentreoftheweld.Figure1-26
illustratesmulti-runtechniqueandFigure1-27shows
the effects of pausing at the edge of weave and of
weaving too rapidly.
3. Overhead Welds
Apart from the rather awkward position necessary,
overhead welding is not much more difficult that
down hand welding.
Set up a specimen for overhead welding by first tack-
ing a length of angle iron at right angles to another
piece of angle iron or a length of waste pipe. Then
tack this to the work bench or hold in a vice so that
the specimen is positioned in the overhead position
as shown in the sketch.
Other Knowledge
& Resources
Please refer to Euroquip website
www.euroquip.co.nz/ Downloads.html
for knowledgebase articles & operation videos.
17
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EZITIG 180
MMA Troubleshooting
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EZITIG 180
Tig Welding Techniques
Tig Welding Fusion Technique
ManualTIGweldingisoftenconsideredthemostdif-
ficult of all the welding processes. Because the welder
must maintain a short arc length, great care and skill
are required to prevent contact between the electrode
and the work piece. Similar to Oxygen Acetylene torch
welding, TIG welding normally requires two hands
and in most instances requires the welder to manu-
ally feed a filler wire into the weld pool with one hand
while manipulating the welding torch in the other.
However,someweldscombiningthinmaterialscan
be accomplished without filler metal like edge, cor-
ner, and butt joints.
ThisisknownasFusionweldingwheretheedgesof
the metal pieces are melted together using only the
heatandarcforcegeneratedbytheTIGarc.Oncethe
arc is started the torch tungsten is held in place until a
weld pool is created, a circular movement of the tung-
sten will assist is creating a weld pool of the desired
size. Once the weld pool is established tilt the torch
atabouta75°angleandmovesmoothlyandevenly
along the joint while fusing the materials together.
of the molten pool, the arc will melt the filler wire into
the weld pool as the torch is moved forward. Also a
dabbing technique can be used to control the amount
of filler wire added, the wire is fed into the molten
pool and retracted in a repeating sequence as the
torchismovedslowlyandevenlyforward.Itisim-
portant during the welding to keep the molten end of
the filler wire inside the gas shield as this protects the
end of the wire from being oxidised and contaminat-
ing the weld pool.
TIG Welding Guide
Tig Welding with Filler Wire Technique
InmanysituationswithTIGwelding,itisnecessary
to add a filler wire into the weld pool to build up weld
reinforcement and create a strong weld. Once the arc
is started the torch tungsten is held in place until a
weld pool is created, a circular movement of the tung-
sten will assist is creating a weld pool of the desired
size. Once the weld pool is established tilt the torch
atabouta75°angleandmovesmoothlyandevenly
along the joint. The filler metal is introduced to the
leading edge of the weld pool. The filler wire is usually
heldatabouta15°angleandfedintotheleadingedge
Travel Direction
75o
Formaweldpool Angle torch Movethetorchslowly
and evenly forward
75o
Travel Direction
Formaweldpool Angle torch AddTIGfillerwire
Retractthefillerwire Movethetorchforwardto
the front of the weld pool
Repeattheprocess
15o
Gas Shield
Electrodes
Tungsten Electrodes
Tungsten is a rare metallic element used for manufac-
turingTIGweldingelectrodes.TheTIGprocessrelies
on tungsten’s hardness and high temperature resist-
ance to carry the welding current to the arc. Tungsten
hasthehighest meltingpointofanymetalat3410
degrees Celsius.
Tungstenelectrodesarenon-consumableandcome
in a variety of sizes, they are made from pure tung-
sten or an alloy of tungsten and other rare earth ele-
ments. Choosing the correct tungsten depends on the
material being welded, the amount of amps required
and whether you are using AC or DC welding current.
Tungstenelectrodesarecolour-codedattheendfor
easy identification.
Thoriated Tungsten Electrodes
Thoriated tungsten electrodes (AWS classification
EWTh-2)containaminimumof97.30percenttung-
stenand1.70to2.20percentthoriumandarecalled2
percent thoriated. They are the most commonly used
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EZITIG 180
electrodes today and are preferred for their longevity
and ease of use.
Thorium increases the electron emission qualities of
the electrode, which improves arc starts and allows
forahighercurrent-carryingcapacity.Thiselectrode
operates far below its melting temperature, which
results in a considerably lower rate of consumption
and eliminates arc wandering. Compared with other
electrodes, thoriated electrodes deposit less tungsten
into the weld puddle, so they cause less weld con-
tamination.
Thoriumisalow-levelradioactivehazardandmany
users have switched to other alternatives. Thorium
is an alpha emitter but when enclosed in a tungsten
matrix, the risks are negligible. Thus holding a stick
of Thoriated tungsten in your hand should not pose
a great threat unless a welder has open cuts on their
skin. Thoriated tungsten should not get in contact
with open cuts or wounds. The more significant dan-
ger to welders can occur when thorium oxide gets
into the lungs. This can happen from the exposure to
vapoursduringweldingorfromingestionofmaterial/
dustinthegrindingofthetungsten.Followthemanu-
facturer’s warnings, instructions, and the Safety Data
Sheet (SDS) for its use.
jagged edges, imperfections, or poor surface finishes
not visible to the eye that will contribute to weld in-
consistency and weld defects.
Always grind the tungsten in a longitudinal direc-
tion. Tungsten electrodes are manufactured with the
molecular structure of the grain running lengthwise
and thus grinding crosswise is “grinding against the
grain.”Ifelectrodesaregroundcrosswise,theelec-
trons have to jump across the grinding marks and
the arc can start before the tip and wander. Grinding
longitudinally with the grain, the electrons flow stead-
ily and easily to the end of the tungsten tip. The arc
starts straight and remains narrow, concentrated, and
stable.
Tungsten Electrode Current Ranges
1.0mm 15-80
1.6mm 70-150
2.4mm 150-250
3.2mm 250-400
4.0mm 400-500
Tungsten DC Current Amps Torch
Diameter Negative 2% Thoriated
Tungsten Preparation
Always use DIAMOND wheels when grinding and
cutting. While tungsten is a very hard material, the
surface of a diamond wheel is harder, and this makes
for smooth grinding. Grinding without diamond
wheels, such as aluminium oxide wheels, can lead to
Grind longitudinal on the
grinding wheel DO NOT grind across the
grinding wheel
Electrode Tip/Flat
The shape of the tungsten electrode tip is an impor-
tant process variable in precision arc welding. A good
selectionoftip/flatsizewillbalancetheneedforsev-
eral advantages. The bigger the flat, the more likely
arc wander will occur and the more difficult it will be
toarcstart.Increasingtheflattothemaximumlevel
that still allows arc start and eliminates arc wonder
will improve the weld penetration and increase the
electrode life. Some welders grind electrodes to a
sharp point, which makes arc starting easier but can
contribute to decreased welding performance due to
the tip me lting and falling into the weld pool.
2.5xTungstenDiameter
Flat
Tip
Pointed
Tip
Electrode Included Angle/Taper
DC Welding Tungsten electrodes for DC welding
should be ground longitudinally and concentrically
with diamond wheels to a specific included angle in
conjunctionwiththetip/flatpreparation.Differentan-
gles produce different arc shapes and offer different
weld penetration capabilities.
20 www.strata.co.nz
EZITIG 180
In general, electrodes that have an appropriate in-
cluded angle and a suitable flat on the tip, exhibit the
following benefits:
• Lastlonger
• Havebetterweldpenetration
• Haveanarrowerarcshape
• Canhandlemoreamperagewithouteroding.
Sharper electrodes with smaller included angle provide:
• Offerlessarcweld
• Haveawiderarc
• Haveamoreconsistentarc
The included angle determines weld bead shape and
size. Generally, as the included angle increases, pen-
etration increases and bead width decreases.
Included
Angle
FlatSpot
Diameter
Tungsten Electrode Preparation
Tungsten
Electrode
Diameter
(mm)
Flat Spot
Diameter
at the Tip
(mm)
Tip
Included
Angle
(Degrees)
Current
Range
(Amps)
Current
Pulsed
(Amps)
1.6 .500 25 08-50 05-10
.800 30 10-70 10-140
2.4 .800 35 12-90 12-180
1.100 45 15-150 15-250
3.2 1.100 60 20-200 20-300
1.500 90 25-250 25-350
TIG Troubleshooting
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